Manual Transmission Maintenance

Is your manual transmission getting harder to shift? Does it feel like it just doesn't grab like it used to? Or maybe it's starting to chatter or vibrate? A worn clutch may be the culprit here. Or it could be the result of something else, such as a transmission misalignment. One obvious sign that this is the problem would be rust residue on the disc and pressure plate.

Pinpoint the Problem
In the case of the Jeep driveline shown here, one of the two transmission dowel pins was missing, which allowed the transmission to tilt down on the passenger's side of the Jeep, causing the misalignment. The input shaft on the transmission was also heavily worn where it rides on the pilot bearing due to the misalignment.


Correcting the cause of the problem is simply a matter of making a new dowel pin for the transmission and installing it. Although this relatively simple fix is just one example of many possible problems that might need to be addressed, the procedure for servicing and re-assembly applies to clutches in general.

Make Adjustments
Prior to putting the clutch back together, the flywheel should be re-surfaced and a new pilot bearing installed in the flywheel, which is always recommended. Other tips include using a drop of Loctite on the threads of the bolts prior to bolting the flywheel to the engine. Also, clean the flywheel and pressure plate with acetone to ensure an oil-free surface (this is one area where you don't want any lubrication at all).


Make sure to use the correct alignment tool when placing the disc up to the flywheel. Once again, before bolting and torquing the pressure plate to the flywheel, apply a drop of Loctite on the threads of the bolts.